Reflex detector counter and monitoring system

ABSTRACT

APPARATUS FOR CONTROLLING WEB BREAK DETECTORS AND ASSOCIATED COMPONENTS, AND MONITORING WEB BREAKS IN MOVING WEB MATERIAL, WHICH DETECTS THE FIRST BREAK IN A WEB AND THEREAFTER PREVENTS DETECTION OF ADDITIONAL AND SUBSEQUENT WEB BREAKS UNTIL AFTER THE APPARATUS IS RESET, RECORDS EACH WEB BREAK ON A COUNTED CORRESPONDING TO ITS LOCATION ALONG THE WEB, AND CONTROLS THE WEB AFTER A BREAK HAS OCCURRED.

REFLEX DETECTOR COUNTER AND MONITORING SYSTEM Filed Nov. 14, 1968' H. F. CLASEN Sept. 20, 1971 3 Sheets-Sheet 1 IN VE' N TOR A TTORNE Y8 HERMAN F. CLASEN w Mia mmnjom hm wwo 1 I mwnzj o zQmmuEE N TQE REFLEX DETECTOR COUNTER AND MONITORING SYSTEM Filed NOV. 14, 1968 H. F. CLASEN Sept. 20, 1971 3 Sheets-Sheet 2 1 FIG-5A 1234567 8 CCCCCCC C L 0 R T w T m E W m ILI Ll ll. l Ll ll [I II II 5 T R MMM RC E F 2 15 w H Q w 0 t c m 1 4W I I23 m mmnwwmzazz TO FIG-5B ep 20, 1971 H. F. CLASEN 3,605,513

REFLEX DETECTOR COUNTER AND MONITORING SYSTEM Filed Nov. 14. 1988 3 Sheets-Sheet 5 FIG 5B 1 r\ -14.; f I 4: L 2 3R2 ITR 21 3R5 1 TS CRT 29 1 n P 3o 3R6 WSR 3| N G 1 C82 FIG6 LL] T. LLZ --220 V.

IWSR 321 38 STARTER United States Patent 3,605,618 REFLEX DETECTOR COUNTER AND MONITORING SYSTEM Herman F. Clasen, 636 N. Main St., Germantown, Ohio 45327 Filed Nov. 14, 1968, Ser. No. 775,620 Int. Cl. 1341f 33/14 US. Cl. 101-428 9 Claims ABSTRACT OF THE DISCLOSURE Apparatus for controlling web break detectors and associated components, and monitoring web breaks in moving web material, which detects the first break in a web and thereafter prevents detection of additional and subsequent web breaks until after the apparatus is reset, records each web break on a counter corresponding to its location along the web, and controls the web after a break has occurred.

BACKGROUND OF THE INVENTION Detector systems for use on moving web material have in the past been responsive to each and every web break occurring along the web. For example, when a break occurred in the first half of a printing press the detectors in the second half of the press would usually fall because of the slackening of the web. Such web break detecting systems thus detected numerous false breaks in the web without pinpointing the position of the actual break. The area of the press which required mechanical repair was therefore left open to speculation. Further, where severing devices are incorporated in such web break detecting systems, the web would not only be severed in the position of the fault but also in the area of slackening. Many times the press crew would be unable to determine the precise position of the first web break and would therefore be required to remove all severed sections of the web thus necessitating rewebbing of the entire press rather than rewebbing only in the area of the actual fault.

Another problem inherent in previous detecting systems was inadvertent detections of slight fluctuations in web tension caused by detectors which were improperly constructed or too sensitive. This resulted in unnecessary down-time for trouble shooting the system to determine which was the offending detector.

SUMMARY OF THE INVENTION The present invention employs apparatus which includes a reflex circuit wherein a plurality of detector units are located at predetermined regions along a moving web. A control relay means cooperates with and is actuated by any one of said detector units to simultaneously stop the movement of the web, and set up a holding circuit for the detector unit first detecting a web break such that any additional and subsequent web breaks are not effective to actuate the system. Individual counters responding to each detector unit monitor the number of web breaks occurring in a particular region over a period of time to continuously indicate the areas requiring mechanical attention. Also, a counter is employed for monitoring the total number of web breaks occurring over the entire web over a corresponding period of time.

Incorporated into the system is conventional apparatus for controlling the web after a break occurs to facilitate rewebbing of the press. A plurality of trolley devices pinch the web and prevent it from moving sideways or flapping. The trolley devices hold the broken web only until the movement of the entire web has stopped. A plurality of web shears sever the broken web in the vicinity 3,605,618 Patented Sept. 20, 1971 of the break to facilitate rethreading of the web through the press.

Also, an automatic cylinder throw-off timer initiates the removal of printing cylinders from the web in timed relation with the paster cycle of an automatic paster in the usual manner, in order to permit a paster joint to pass through the press. Individual counters record the number of paster cycles attempted and completed thereby enabling the number of web breaks occurring during paster operations to be determined.

BRIEF DESCRIPTION OF THE DRAWINGS The invention will be hereafter more fully described with reference to the accompanying drawings, in which:

FIG. 1 is a schematic side view of the path traversed by a web through a typical printing press;

FIG. 2 is side view illustrating a preferred embodiment of a detector unit;

FIG. 3 is a top view of a detector unit, showing a cantilevered support;

FIG. 4 is a partial view taken along line 44 of FIG. 3 of the cam operated switching means associated with a detector unit;

FIGS. 5A and 5B show the circuitry which includes the detectors, counters, web break relay, trolley device relay, and web shear relay; and

FIG. 6 shows the circuitry which includes the Web shears, trolley devices, starter, and drive means.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to the figures of the drawings, for purposes of illustration, FIG. 1 depicts a typical path along which a web 10 travels through a printing press. The path of the web commences with reel 12 which is shown as including three rolls of paper 14, 16 and 18. As herein illustrated, the web 10 is being unravelled from roll 14 and a plurality of rollers 20 are guiding it along its path.

Web speed control mechanism 22, which is connected to web speed indicator 24 and drive means 25, enables the speed of the web to be gradually increased from threading speed to full speed. Web speed indicator 24 is operatively connected to speed responsive switches CS1 and CS2 (FIG. 5).

In its path, the web traverses detector DSl, located in the area of the reel 12, from which it travels to detector DS2 located just ahead of a roller 20 leading into the first impression cylinders 30. As shown, a plurality of first impression cylinders are located on the circumference of the large cylinder 32. Web shear is positioned just ahead of the first impression cylinders. After traversing the cylinders 30, the web passes trolley device 36 and detector DS3 and enters dryer 40. The web is'delivered from the dryer 40 past detector D84, web shear 45, between second impression cylinders 46 and large impression cylinder 47, and past trolley device 48, and detector DS5 which are positioned just ahead of its second pass through dryer 40. After leaving the dryer 40 for the second time, the web passes trolley device 49 and detector D86 and enters the web folder 50 which includes a plurality of rollers 52 for leading the web past web shear 55 and into folder cylinders 57 from which the web is finally delivered from the press via conveyor 59.

Drive means 25 provides power to the paster mechanism 60 which includes a web severing device and a web pasting device (not shown). In operation, the automatic paster 60 will sever the end of the web on roll 14, paste the end obtained from roll 14 to the beginning of the web on roll 16 to form a paster joint, and simultaneously turn the reel 12 in a counter-clockwise direction such that the Web will continue to flow without interruption. A fresh roll of paper may be placed on roll 14 after it has been moved to the position of roll 18 in order that the cycle may be repeated.

Drive means 25 drives large cylinder 32, large cylinder 47, and the rollers 52 and folder cylinders 57 of the folder 50. Web speed control mechanism 22 is used to inch the web along while threading a new or broken web through the press. It may also be used to gradually increase the speed of the web until the desired full rate of speed is attained.

A typical detector unit, for example, D51, is shown in FIGS. 2-4 as including a body 70 housing a normally open switching means 72 and a contact member 74 pro truding from body 70 and connected to said switching means 72. The detector units may be held over the web by means of a cantilever 75 (FIG. 3), or by any other suitable means. A pair of vertical support members 76 extend from the body 70 and support a pivotally mounted cross-bar 78. Arm member 80 supports a roller 82 which rests on the moving web at one end and is fixedly attached by means of pin 81 to pivotal cross-bar 78 at the other end. Cam 84 is fixedly attached to the pivotal cross-bar 78 opposite contact member 74 such that the cam 84 will not engage the contact member 74 when the Web is taut. When a break occurs in the web, the weight of the arm member 80 will no longer be supported by a taut web 10 and the cross-bar 78 will pivot downwardly to bring the cam 84 in contact with the contact member 74 thereby closing the switching means 72 and engaging the corresponding detector relay.

Referring now to FIG. 5, it will be seen that a 110 v. source exists between L1 and L2. A 220 v. source exists between L11 and L22 and provides power through the starter to the drive means 25. The normally open switch CS1 is preset to be responsive to a web speed somewhat above threading speed. After the web has been threaded through the press, the speed of the web is gradually increased by means of web speed control mechanism 22. Web speed indicator 24, which is operatively connected to switch CS1, will close switch CS1 when the preset speed or CS1 speed setting is attained. This will provide a path of power to the detectors DSl-DS6 through normal 1y closed switch 2CR. Each detector, for example, DSS, is illustrated in the circuit by means of a normally open switch corresponding to the open position of each contact member 74 and cam 84, shown in FIGS. 2 and 4 as occurring when a detector rests on a taut Web. Each detector DS1-DS6 is operatively connected through an individual diode D1-D6 to an individual relay Rl-R6. Six detectors have been utilized in this application for purposes of illustration only. It is to be understood that additional detectors could be added to the system without departing from the scope of the invention.

When a web break occurs after the CS1 speed has been attained, for example, in the area of the reel 12, the detector switch DS1 will close and energize its respective relay R1. Relay R1 will simultaneously actuate its corresponding holding circuit contact 1R1 to thereby immediately establish a holding circuit through contact 1R1 (via line 5) and also cause pilot light E1 to light thereby telling the operator where the break has occurred. Simultaneously, R1 will actuate its corresponding second relay contact 2R1 and establish a count on counter C1 which counts the breaks at the reel. Also simultaneously, relay R1 will energize its third relay contact 3R1 (line thereby energizing control relay CR and trolley device timer lTR. The control relay CR, which has three contacts 1CR, 2CR and 3CR, will initially close normally open switch 1CR which will actuate web break relay WBR and open normally closed switch IWBR (line 38) to cutoff power to drive means 25 and stop movement of web 10. Further, control relay CR will simultaneously open normally closed switch 2CR and cut oif power to the detectors via switch CS1. In this manner, an additional and subsequent break in the web will not actuate the circuit because there is no path by which the detector in the region of the additional and subsequent web break can become actuated. The current flowing through the holding circuit keeps relay R1 energized and diode D1 prevents current from passing through switch DS1 to the other detectors. Control relay CR also actuates contact 3CR to establish a count on counter C3 which counts the total web breaks occurring along the entire web.

In the course of actuating the control relay CR each detector relay also actuates the trolley device timer 1TR via any of the 3R contact points to which power is fed from line 25. Trolley device timer 1TR is preset to close momentarily the switch TS and thus energize the trolley device relay CRT. The trolley device timer lTR is preferentially preset for the approximate amount of time required for the particular press to stop after a web break is detected. Once the trolley device relay CRT is energized it will actuate contacts lCRT, ZCRT and 3CRT, effectively bringing trolley devices 36, 48 and 49, illustrated in the circuit as solenoids, into pinching relation with the web to prevent lateral movement thereof. Trolley device timer ITR Will be deenergized when the preset time elapses to disconnect switch TS and release the trolley devices from the web.

The previously described operations take place when any one of the detector units DS1-DS6 falls due to a break in a web traveling above CS1 speed. Restated in simplified terms, energization of a detector relay simultaneously stops forward and lateral movement of the web, identifies the location of the fault, establishes a holding circuit independently of the switching means, registers a count on a total counter, and registers a count on a regional counter. The apparatus thus controls and monitors web breaks and, more particularly, prevents additional and subsequent Web breaks from energizing detector relay until after the operators have placed all detector units on a taut web and have reset the apparatus. The reset button RB (see FIG. 5, lines 3, 5 and 16) will close contact ZCR and open the corresponding holding circuit contact to re store the circuit to its original operational condition.

The apparatus is constructed such that web shears 35, 45 and 55 are rendered operable only after the web has attained a speed higher than jog speed. Normally open switch CS2 controls power to the Web shears and, being responsive to web speed, is closed only when web speed detector 24 indicates a preset CS2 speed or higher. The CS2 speed setting will be above the CS1 speed setting and will preferentially approach full web speed.

Because it is preferable to sever a fast-moving broken web before it can clog or damage the precision cylinders, web shears 35 and 45 are located ahead of impression cylinders 30 and 46, respectively and web shears 55 are placed ahead of folding cylinders 57. The number and location of the web shears have been used for representation purposes only and are not intended to limit the scope of the present invention.

The web shears, represented in FIG. 6 as solenoids, depend upon the actuation of a fourth 4R contact for their operation. These contacts are, however, locked out of the circuit by means of web shear relay contact IWSR which will permit power to be supplied to the 4R contacts only after switch CS2 energizes the web shear relay WSR.

Detector DSl does not have a web shear 4R contact because it is located in the vicinity of the reel 12. Hence, none of the Web shears will be actuated by a web break in the DS1 vicinity even though power has been established through the lock-out means to the web shear contacts.

A web shear will only be actuated if a break occurs at a web speed above CS2 speed and in the vicinity of either the first impression cylinders, the second impression cylinders, or the folding cylinders. For example, if a web break occurs at DSS, its corresponding relay R5 will not only set all the operations effective at a web speed above the CS1 speed into operation, but will also actuate web shear contact 4R5 (FIG. 6) and cause web shear 45 to sever the web ahead of second impression cylinders 46. Thus the shears will not sever the web when a break occurs above the CS1 speed and below the CS2 speed. This keeps as much of the web in the press as possible and minimizes re-threading. The shears will be capable of severing the web only after the CS2 speed is attained.

It is obvious that any combination of detector relays can be utilized in conjunction with the web shears. As shown in FIG. 6, each of the detector relays on the in and out side of the first impression cylinders, relays R2 and R3, will actuate web shears 35. Likewise, each of the detector relays on the in and out side of the second impression cylinders, relays R4 and R5, will actuate web shears 45. Detector relay R6 associated with the folder 50 actuates web shears 55.

Each counter C1-C6 corresponding to each detector unit DS1-DS6, registers the number of breaks in a particular region of the web. If counter C1 registers one break and counter C4 registers 20 breaks after a week of press operation, it will be quickly apparent that the area on the out side of the second impression cylinders requires more mechanical repair and attention than the area of the reel. Quick detection of areas of mechanical fault can reduce the total number of web breaks. This latter figure is monitored on counter C7.

The reflex effect of the circuitry enables the area of fault to be accurately pinpointed without the interference of additional and subsequent false detections caused by slackening of the web after a break has occurred. The circuit will also quickly pinpoint the improperly constructed detector unit or the faulty detector units which are not only sensitive to actual web breaks but also to slight fluctuations in web tension.

It is quickly apparent that any number of detectors, counters, trolleys, web shears, as well as other supplementary equipment, can be easily incorporated into the present apparatus. As an example, automatic paster mechanism 60 has been connected to the circuit. Normally open switch T is operatively connected to a device (not shown) which signals that the end of the roll of paper is near. This closes switch T and energizes automatic cylinder throw-01f timer ET. As soon as the paster knife (now shown) cuts the end of the web on roll 14, throw-off timer ET signals a mechanism (not shown) to remove the impression cylinders from the large cylinders to permit a paster joint to pass through the press. Contact lET closes when the paster knife cuts thereby establishing a count on counter C8 which counts the number of paster cycles attempted. The timer ET is preset to close contact ET after the paster joint is through the press to establish a count on counter C9 which counts the number of paster cycles completed. The number of web breaks occurring during the paster cycles over a period of time may easily be determined by subtracting the number of paster cycles completed, counts on C9, from the number of paster cycles attempted, counts on C8.

Reset button RB (line 3) must be depressed after a broken web has been re-threaded in order to open switch 2CR andrelease the holding circuit. This will reestablish power to the detector units, cut off power to the respective holding contact, deenergize the respective detector relay and the control relay CR, and return the apparatus to its original state in preparation for detection of an additional and subsequent break.

The reset button RB provides a further operational advantage. In the normal threading operation the detector units are moved to an up position and placed on a hook or other suitable means to keep them out of the path of the web. When in this position each contact member 74 will be engaged by each cam 84 thus providing a path for current to pass to the pilot lights E1-E6. However, since the web is not running above the CS1 speeds, switch CS1 will not permit current to pass along this path. As the web is threaded through the press, the detector units are taken off the hook and placed on the taut web. The pressman can easily check to see if the press crew has mistakenly left one of the detector units on the hook. By depressing reset button RB, he will disengage the counter circuit (line 16) which will guard against a false count, short out the holding contact circuit (line 5-6); and momentarily establish current through the detector circuit (line 3) to light the pilot lights of the detectors on the hook thereby indicating which detectors must yet be placed back on the web before the Web speed can be increased.

-It can be seen, therefore, that the preferred embodiment of the present invention provides apparatus including a reflex circuit for accurately pinpointing the first break to occur along a moving web and for preventing detection of additional and subsequent breaks until after the apparatus is reset to operation conditions. The apparatus provides means for controlling a web after a break occurs and means for monitoring the relative frequency of web breaks in various regions of a printing press. This latter aspect of the invention is particularly advantageous for keeping a press under continuous maintenance surveilance.

While the form of apparatus herein described constitutes a preferred embodiment of the invention, it is to be understood that the invention is not limited to this precise form of apparatus, and that changes may be made therein without departing from the scope of the invention.

What is claimed is:

1. In combination with web handling apparatus including web support means and web driving means, an improved web break monitoring system comprising:

(a) a plurality of web break detector units positioned in predetermined regions along the web, each unit sensing movement of the web in the corresponding region,

(b) means for actuating each said unit in response to a web break within the corresponding region,

(c) means for deactivating said web drive means in response to actuation of any one of said units,

(d) a separate counting means for each of said detector units and responsive to actuation of the corresponding said unit for registering the number of actuations of said unit, and

(e) control means responsive to that first actuation of one of said units for permitting the counting means corresponding to that one said unit to register the web break and for rendering ineffective the counting means for the other said units.

2. The Web break monitoring system defined in claim 1 wherein said control means comprises:

(a) separate detector relays responsive to the actuating means in each detector unit,

(b) separate holding circuits responsive to actuation of the detector relays for each detector unit, and

(c) a control relay responsive to the first actuation of one of said detector relays for cutting oif power to said web driving means to stop movement of said web.

3. Apparatus as defined in claim 2 further comprising a plurality of trolley devices located along the path of the web for pinching said web after a web break is detected thereby preventing side motion and flapping of the broken web;

a trolley device relay for actuating said plurality of trolley devices;

a trolley device timer operatively connected with each of said detector relays and arranged to run for a period of time after a web break is detected; and

a switch controlled by said trolley device timer for energizing said trolley device relay for said period of time after a web break is detected.

4. Apparatus as defined in claim 3 wherein the time period of said trolley device timer is such as to release said trolley devices after the web is stopped.

5. Apparatus as defined in claim 2 further comprising a plurality of web shears located along the path of a moving web each located in the vicinity of at least one of said detector units and each operatively controlled by the detector relays associated with said detector units.

6. Apparatus as defined in claim 5 further comprising lock out means for stopping power to any of said Web shears; and

means responsive to Web speed for controlling said lock out means and for establishing power through said lock out means to any of said web shears.

7. Apparatus as defined in claim 2 for use in combination with an automatic paster on a printing press, comprising an automatic cylinder throwoif timer for initiating the removal of the printing cylinders from the web in timed relation with a paster cycle;

means for connecting said automatic paster with said automatic cylinder throwoif timer at the beginning of a paster cycle;

a counter operatively connected with said automatic cylinder throwoff timer for recording the number of paster cycles started; and

a counter operatively connected with said automatic cylinder throwoff timer for recording the number of paster cycles completed.

18-. Apparatus as defined in claim 7 wherein the time period of said automatic cylinder throwolf timer is such as to permit a paster joint to pass through the printing press.

9. Apparatus as defined in claim 2 adapted for use in combination with an automatic paster on a printing press comprising means for permitting paster joints to pass unobstructed through the printing press; and

means for counting the number of web breaks occurring during a paster cycle.

References Cited UNITED STATES PATENTS Re. 21,319 1/11940 Tornberg 2425 8.1X 1,245,410 11/1917 Walkup 101-228 1,251,286 12/1917 Rodman i 10l228X 1,968,166 7/ 1934 Phythian et a1 226--11X 2,248,043 7/1941 Degnan 101181X 2,6535 36 9/ 1953 Cooksey 2261 1X 2,911,908 11/1959 Johnson 101-181 3,096,233 7/ 19-63 Rappaport et a1 226-11X 3,167,865 2/ 1965 Steinberg 24258.1X 3,317,734 5/ 1967 Martin 2261 1X 3,323,701 6/1967 Gurski et a1. 226-43 CLYDE I. COUGHENOUR, Primary Examiner US. Cl. X.R. 

